Apparatus for assembling a battery

ABSTRACT

The method of heating a battery case with a case heater is disclosed comprising the steps of rapidly moving the case heater into engagement with the battery case. After engagement of the case heater with the battery case, the case heater is slowly moved a predetermined distance to melt the battery case.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of application Ser. No. 09/088,158filed Jun. 1, 1998, now U.S. Pat. No. 6,038,962. Application Ser. No.09/088,158 filed Jun. 1, 1998 is a divisional of application Ser. No.08/949,798 filed Oct. 14, 1997, now U.S. Pat. No. 5,900,030, and claimsbenefit of U.S. Patent Provisional application serial No. 06/028,394filed Oct. 15, 1996. All subject matter set forth in provisionalapplication serial No. 06/028,394 is hereby incorporated by referenceinto the present application as if fully set forth herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the construction of electrical storagebatteries and more specifically, to an improved apparatus for assemblinga battery.

2. Background of the Invention

The fabrication and assembly of an electric storage battery such as alead acid storage battery have undergone major changes over the decades.The changes in the fabrication and assembly of an electric storagebattery have been implemented to increase the reliability of theelectric storage battery, to reduce the material cost of the electricstorage battery and reduce the labor cost associated with the assemblyof the electric storage battery.

Many assembly processes of the electric storage battery have beenautomated to reduce the overall cost of manufacture. One process in theassembly of the electric storage battery that has been automated is theprocess of sealing a battery case closure to a battery case.

Typically, the battery case comprises a rectangular open top case havinga plurality of intercell partition walls. A plurality of battery platesare respectively received between the plurality of intercell partitionwalls for forming a plurality of battery cells. The plurality of batteryplates between the plurality of partition intercell walls areinterconnected by intercell connectors extending through or over theintercell partition walls. The intercell connectors connect theplurality of battery plates between the plurality of partition intercellwalls in an electrical series configuration.

In most battery designs, a positive and negative battery post extendsupwardly from the battery plates at opposed ends of the battery case forproviding a positive pole at one end of the battery case and a negativepole on the other end of the battery case. In these battery designs, thepositive and negative battery posts extend above the level of thebattery case.

In many battery designs, a battery case closure includes a positive andnegative battery bushing secured to the battery case closure. When thebattery case closure is placed over the battery case, the positive andnegative battery posts are received within the positive and negativebushings of the battery case closure. The batter case closure is sealedto the battery case by a heat sealing process. Thereafter, the positiveand negative battery posts are electrically connected to a positive andnegative battery bushings.

The prior art has provided numerous battery case sealing machines forheat sealing a battery case closure to a battery case. In general, thesebattery case sealing machines heated the upper surfaces of thesidewalls, the intercell walls and end walls of the battery case andsimultaneously heat the sidewalls and end walls of the battery caseclosure. After the battery case and battery case closure were at leastpartially molten, the battery case closure was moved into engagementwith the battery case allowing the molten surfaces of the battery caseclosure and the battery case to unite for sealing the battery caseclosure to the battery case.

Unfortunately, the battery case sealing machines of the prior art hadnumerous disadvantages Firstly, the battery case sealing machines of theprior art did not always provide a uniform seal about the upper surfaceof the sidewalls, the intercell walls and end walls of the battery case.Secondly, the battery case sealing machines of the prior art were largeand occupied a substantial volume on a production battery assembly line.Thirdly, the battery case sealing machines of the prior art were slow inoperation. Fourthly, the battery case sealing machines of the prior artrequired an extensive amount of time for altering the machine foraccommodating for a different size of battery case.

Therefore, it is an object of the present invention to provide animproved apparatus and method for assembling a battery.

Another object of this invention is to provide an improved apparatus forsealing a battery case closure to a battery case that overcomes thedifficulties of the prior art battery case sealing machines.

Another object of this invention is to provide an improved apparatus forsealing a battery case closure to a battery case incorporating a uniquesingle column configuration for providing increased accuracy and speedof the operation of the apparatus.

Another object of this invention is to provide an improved apparatus forsealing a battery case closure to a battery case incorporating a uniquesingle column configuration for providing increased accessibility to theapparatus for easy cleaning and alteration.

Another object of this invention is to provide an improved apparatus forsealing a battery case closure to a battery case for providing increasedspeed in interchanging a heater platen for accommodating for a differentsize battery case.

Another object of this invention is to provide an improved apparatus forsealing a battery case closure to a battery case with independentcontrol of the melting time of the battery case and the battery closure.

Another object of this invention is to provide an improved apparatus forsealing a battery case closure to a battery case with increased controlof the melting depth of the battery case and the battery closure.

Another object of this invention is to provide an improved apparatus forsealing a battery case closure to a battery case with increased controlof the pressure of engagement between the melted battery closure and themelted battery case.

Another object of this invention is to provide an improved apparatus forsealing a battery case closure to a battery case with increased controlof the time of engagement between the melted battery closure and themelted battery case.

Another object of this invention is to provide an improved apparatus forsealing a battery case closure to a battery case having improvedalignment between the battery closure and the battery case.

Another object of this invention is to provide an improved apparatus forsealing a battery case closure to a battery case incorporating animproved conveyor for moving the battery case relative to the apparatus.

Another object of this invention is to provide an improved apparatus forsealing a battery case closure to a battery case incorporating anautomated battery closure loader for automatically loading the batterycase closures on the apparatus.

Another object of this invention is to provide an improved apparatus forsealing a battery case closure to a battery case incorporating a batteryclosure conveyor for sequentially moving a plurality of battery casecovers to the apparatus for automatic loading thereon.

Another object of this invention is to provide an improved apparatus forsealing a battery case cover to a battery case for providing increasedspeed in interchanging a battery closure receiver for accommodating fora different size battery case.

Another object of this invention is to provide an improved apparatus forsealing a battery case closure to a battery case incorporating arotatable closure receiver being rotatable about a horizontal axis forenabling a closure to be loaded onto the closure receiver while abattery closure is awaiting heating by the apparatus.

Another object of this invention is to provide an improved apparatus andmethod for assembling a battery having a device for moving a carrierwith fluid pressure through fluid conduits disposed internal a shaft.

Another object of this invention is to provide an improved apparatus andmethod for assembling a battery having a novel case stop for stoppingand positioning a battery case on a support.

Another object of this invention is to provide an improved apparatus andmethod for assembling a battery having a control system for controllingthe movement of a case heater during a battery case heating process.

Another object of this invention is to provide an improved apparatus andmethod for assmelbing a battery having a conveyor for sequentiallymoving a plurality of flat battery components such as case closures.

The foregoing has outlined some of the more pertinent objects of thepresent invention. These objects should be construed as being merelyillustrative of some of the more prominent features and applications ofthe invention. Many other beneficial results can be obtained by applyingthe disclosed invention in a different manner or modifying the inventionwith in the scope of the invention. Accordingly other objects in a fullunderstanding of the invention may be had by referring to the summary ofthe invention, the detailed description describing the preferredembodiment in addition to the scope of the invention defined by theclaims taken in conjunction with the accompanying drawings.

SUMMARY OF THE INVENTION

The present invention is defined by the appended claims with specificembodiments being shown in the attached drawings. For the purpose ofsummarizing the invention, the invention relates to an improvedapparatus for sealing a battery case closure to a battery casecomprising a horizontal conveyor for moving the case into a sealingposition adjacent to a vertical column. A platen carrier is verticallyand rotationally movable relative to the column. A platen is mounted tothe platen carrier with the platen comprising a case heater. A receivercarrier is vertically movable relative to the column. A closure receiveris mounted to the receiver carrier with the closure receiver having aclosure retainer for retaining a closure thereby. A platen carrier drivevertically and rotationally moves the platen carrier to locate the caseheater for heating the case thereby. The platen carrier drive verticallyand rotationally moves the platen carrier to relocate the case heaterfrom heating the case. A receiver carrier drive vertically moves thereceiver carrier to position the closure into engagement with the caseto heat seal the closure to the case.

In a more detailed embodiment of the invention, the apparatus includes abase for supporting the vertical column and an adjuster interposedbetween the base and the vertical column for adjusting the verticalpositions of the receiver carrier and the closure receiver relative tothe horizontal conveyor for accommodating for different size batterycases. The adjuster may be a jack interposed between the base and thevertical column. In another embodiment of the invention, the batterycase is a plastic battery case and the horizontal conveyor comprises anon-stick belt for inhibiting the accumulation of melted plastic on thenon-stick belt.

Preferably, the plate is removably mounted to the platen carrier forenabling the platen to be changed for accommodating for different sizebattery cases. The closure receiver is removably mounted to the receivercarrier for enabling the closure receiver to be changed foraccommodating for different size battery cases. The platen includes aclosure heater with a thermal insulator being disposed between the caseheater and the closure heater for enabling the closure heater to beoperated at a temperature independent of the case heater.

The platen carrier drive comprises the platen carrier defining a firstand a second end. A first and a second seal is disposed at the first anda second ends of the platen carrier for sealing with the column. Anannular projection extends from the column and is located between thefirst and second seals for defining a first and a second platen chamber.An input and an output channel communicates with each of the first andsecond platen chambers. A fluid pump pumps a fluid through selectiveinput and output channels for expanding one of the first and secondplaten chambers and for contracting the other of the first and secondplaten chambers for vertically moving the platen carrier relative to thecolumn. In one embodiment of the invention, the input and outputchannels extends within the column.

In another embodiment of the invention, the closure retainer comprises aplurality of apertures defined in the closure receiver and communicatingwith a vacuum source for retaining a closure on the closure receiver.

The invention may include a closure feeder for sequentially introducinga plurality of closures to the closure receiver. The closure feedercomprises a closure conveyor for moving the plurality of closures to atransfer arm. The transfer arm sequentially transfers the plurality ofclosures to the closure receiver.

The invention may include a closure receiver being rotatably mountedabout a horizontal axis to the receiver carrier. The closure receiverhas a closure retainer for retaining a closure thereby. The closurereceiver has a first and a second closure receiver portion disposed onopposed sides of closure receiver. A closure receiver rotating driverotates the closure receiver to a first rotational position for enablingthe first closure receiver portion to receive a first closure. Theclosure receiver rotating drive rotates the closure receiver to a secondrotational position for enabling the second closure receiver portion toreceive a second closure.

The invention is also incorporated into an apparatus for moving acarrier with fluid pressure. The apparatus comprises a shaft having anannular piston extending from said shaft. A carrier drive drives thecarrier. The carrier drive comprises a cylindrical barrel extendingbetween a first and a second end members. The cylindrical barrel is insealing engagement with said annular piston with said first and secondend members being located on opposed sides of said annular piston. Afirst and a second seal coacts between said first and second end membersand said shaft for defining a first and a second chamber. A first and asecond channel extend through said shaft to communicate with said firstand second chambers, respectively. A valve system connects the fluidpressure to said first and second channels for enabling said firstchamber to expand upon the introduction of fluid pressure into saidfirst chamber for moving said carrier drive in a first directionrelative to said shaft. The valve system enables said second chamber toexpand upon the introduction of fluid pressure into said second chamberfor moving said carrier drive in a second direction relative to saidshaft.

The invention is also incorporated into a case stop for stopping andpositioning a battery case on a support. The case stop comprises a stopframe movably mounted relative to the support. A major and a minor casestop are located on said stop frame. The major case stop initiallypositions the battery case upon initial movement of said stop frame. Theminor case stop subsequently positions the battery case upon continuedmovement of said stop frame.

The invention is also incorporated into the method of heating a batterycase with a case heater. The method comprises rapidly relatively movingthe case heater and the battery case into mutual engagement and slowlyrelatively moving the case heater and the heated battery case apredetermined distance to melt the battery case on a predetermineddistance.

The invention is also incorporated into a conveyor for sequentiallymoving a plurality of flat battery components. The conveyor systemcomprises a conveyor having a plurality of separators for receiving aflat battery component between each of adjacent separators. The conveyorsupports an end of each of the flat battery components with each of theplurality of the flat battery components being maintained on end by theplurality of separators. A motor drive moves the conveyor for moving theplurality of flat battery components thereby.

The foregoing has outlined rather broadly the more pertinent andimportant features of the present invention in order that the detaileddescription that follows may be better understood so that the presentcontribution to the art can be more fully appreciated. Additionalfeatures of the invention will be described hereinafter which form thesubject of the claims of the invention. It should be appreciated bythose skilled in the art that the conception and the specificembodiments disclosed may be readily utilized as a basis for modifyingor designing other structures for carrying out the same purposes of thepresent invention. It should also be realized by those skilled in theart that such equivalent constructions do not depart from the spirit andscope of the invention as set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and objects of the invention,reference should be made to the following detailed description taken inconnection with the accompanying drawings in which:

FIG. 1 is a front view of an apparatus incorporating the presentinvention;

FIG. 2 is a right side view of FIG. 1;

FIG. 3 is a view along line 3—3 in FIG. 1;

FIG. 4 is a top view of FIG. 1;

FIG. 5 is an enlarged view of a portion of FIG. 1;

FIG. 5A is a sectional view along line 5A—5A in FIG. 5;

FIG. 5B is a sectional view along line 5B—5B in FIG. 5;

FIG. 6 is a view similar to FIG. 5 with a heating platen moved into aretracted position;

FIG. 6A is a sectional view along line 6A—6A in FIG. 6;

FIG. 6B is a sectional view along line 6B—6B in FIG. 6;

FIG. 7 is an enlarged exploded isometric view of a heater platen of thepresent apparatus;

FIG. 8 is an assembled isometric view of the heater platen of FIG. 7;

FIG. 9 is an enlarged partial view of FIG. 8;

FIG. 10 is an enlarged exploded isometric view of a closure receiver ofthe present apparatus;

FIG. 11 is an assembled isometric view of the closure receiver of FIG.10;

FIG. 12 is an enlarged partial view of FIG. 11;

FIG. 13 is an enlarged view of a column of the present invention in afirst adjusted position;

FIG. 13A is an enlarged view of the column of the present invention in asecond adjusted position;

FIG. 14 is an enlarged view of the column of the present inventionillustrating the closure receiver in a lowered position;

FIG. 14A is an enlarged view of the column of the present inventionillustrating the closure receiver in a raised position;

FIG. 15 is an enlarged view illustrating the platen in a raisedposition;

FIG. 16 is an enlarged view illustrating the platen being moved into alowered position;

FIG. 17 is an enlarged view illustrating the platen being moved intoengagement with the battery case;

FIG. 18 is an enlarged isometric view of a battery case stop in a firstposition;

FIG. 19 is an enlarged isometric view of a battery case stop in a secondposition;

FIG. 20 is an enlarged isometric view of a battery case stop in a thirdposition;

FIG. 21 is an enlarged partial view of FIG. 1 illustrating a batterycase closure loader assembly in a first position;

FIG. 22 is a view illustrating the battery case closure loader assemblyin a second position;

FIG. 23 is a view illustrating the battery case closure loader assemblyin the first position with a battery case closure thereon;

FIG. 24 is a view illustrating the battery case closure loader assemblyin a third position with the battery case closure thereon;

FIG. 25 is a view illustrating the battery case closure loader assemblyin a fourth position for placing the battery case closure on a closurereceiver;

FIG. 26 is a view illustrating the battery case closure loader assemblyin a third position with the battery case closure thereon;

FIG. 27 is a diagram of the present apparatus illustrating an initialstate of the apparatus;

FIG. 28 is a diagram of the present apparatus illustrating a firstbattery case closure place on a first closure receiver portion as wellthe movement of a first battery case;

FIG. 29 is a diagram of the present apparatus illustrating a rotation ofthe second carrier portion;

FIG. 30 is a diagram of the present apparatus illustrating therotational movement of the movement of the heating platen;

FIG. 31 is a diagram of the present apparatus illustrating the verticalmovement of the second carrier portion and the vertical movement of theheating platen for heating the first battery case closure and the firstbattery case;

FIG. 32 is a diagram of the present apparatus illustrating the verticalmovement of the heating platen and the vertical movement of the closurereceiver for removing the heating platen from the first battery case andthe first closure;

FIG. 33 is a diagram of the present apparatus illustrating therotational movement of the heating platen;

FIG. 34 is a diagram of the present apparatus illustrating the verticalmovement of the closure receiver for sealing the first closure to thefirst battery case;

FIG. 35 is a diagram of the present apparatus illustrating thewithdrawal of the carrier receiver and the movement of the first batterycase;

FIG. 36 is a diagram of the present apparatus illustrating a secondclosure place on a second closure receiver portion;

FIG. 37 is a diagram of the present apparatus illustrating the rotationof the second carrier portion; and

FIG. 38 is a diagram of the present apparatus illustrating the movementof the second battery case.

Similar reference characters refer to similar parts throughout theseveral Figures of the drawings.

DETAILED DISCUSSION

FIG. 1 is a side elevational view of an apparatus 10 for sealing abattery case closure 1 to a battery case 12. FIG. 2 is a right side viewof FIG. 1 whereas FIG. 3 is a view along line 3—3 in FIG. 1 with FIG. 4being a top view of FIG. 1. Although the battery case closure 11 hasbeen shown as a cover, it should be understood that the battery closure11 may be any closure such as a bottom closure or multiple closures suchas a top and a bottom of the battery case or sides of the battery case.

The apparatus 10 comprises a base 20 having a plurality of legs 21-23for supporting a frame 25. The frame 25, supports a horizontal conveyor30 comprising a plurality of rollers 31-33 for suspending an endlessbelt 35. Preferably, roller 31 is driven by a roller drive such as anelectric or fluid motor (not shown) for driving the endless belt 31 andfor moving batteries between an input 41 of the apparatus 10 and anoutput 42. Preferably, the endless belt 31 is made of a non-stickmaterial such as a material sold under the trademark KEVLAR. Thenon-stick material of the endless belt 31 inhibits the accumulation ofmelted plastic material on the non-stick belt from the battery caseand/or battery closure material. Furthermore, the non-stick material ofthe endless belt 31 makes the endless belt 31 easier to remove meltedplastic material from the endless belt 31.

An input conveyor 50 comprises a plurality of legs 51 and 52 forsupporting an input conveyor frame 54. The input conveyor frame 54includes a plurality of rollers 58 for moving battery cases along ahorizontal path into the input 41 of the apparatus 10. Preferably, therollers 58 of the input conveyor 50 are driven by a roller drive such asan electric or fluid motor (not shown) for moving battery cases 12 tothe input 41 of the apparatus 10.

An output conveyor 60 comprises a plurality of legs 61 and 62 forsupporting an output conveyor frame 64. The output conveyor frame 64includes a plurality of rollers 68 for moving battery cases 12 along ahorizontal path from the output 42 of the apparatus 10. Preferably, therollers 68 of the output conveyor 60 are driven by a roller drive suchas an electric or fluid motor (not shown) for moving battery cases 12from the output 42 of the apparatus 10.

FIG. 5 is an enlarged view of a portion of FIG. 1 illustrating theapparatus 10 as comprising a vertical column 70 which is supported bythe base 25. An adjuster 72 is interposed between the base 25 and thevertical column 70 for adjusting the vertical position of the verticalcolumn 70 relative to the horizontal conveyor 30. Preferably, theadjuster 72 is a jack (not shown) incorporating an adjustment handle 74for adjusting the vertical position of the vertical column 70 foraccommodating for a different size battery case 12. Although theadjustment handle 74 is shown as a manual adjustment handle 74, itshould be understood that the manual adjustment handle 74 may beautomatically adjusted through the use of an electric or fluid motor(not shown). Furthermore, the automatic adjustment of the adjustmenthandle 74 may be controlled by computer operation. The adjuster 74rapidly accommodates for a different height battery case for enabling aspeedy changeover for manufacturing a different size of battery.

FIG. 6 is a view similar to FIG. 5 with a platen carrier 80 and a platen82 being moved from a first rotational position shown in FIG. 5 to asecond rotational position shown in FIG. 6. The platen carrier 80 isvertically and rotationally movable relative to the vertical column 70.The platen 82 is mounted to the platen carrier 80 with the platencomprising a case heater 84 and a closure heater 86. The platen carrier80 comprises a cylindrical barrel 88 for vertically and rotationallymounting the platen carrier 80 relative to the vertical column 70.

A platen carrier rotating drive 90 rotates the platen carrier 80 betweenthe first rotary position shown in FIGS. 5, 5A and 5B and a secondrotary position shown in FIGS. 6, 6A and 6B. The platen carrier rotatingdrive 90 includes the cylindrical barrel 88 having a gear 92 cooperatingwith a pinion gear 94. The pinion gear 94 is driven by a motor 96 suchas an electric or fluid motor for moving the platen carrier 80 betweenthe first rotary position shown in FIGS. 5, 5A and 5B and a secondrotary position shown in FIGS. 6, 6A and 6B.

FIG. 7 is an enlarged exploded isometric view of the platen carrier 80and the platen 82. The cylindrical barrel 88 of the platen carrier 80supports a generally U-shape mounting 98. Preferably, the generallyU-shaped mounting 98 is secured to the cylindrical barrel 88 by a pivot99. The generally U-shape mounting 98 includes a first and a second slot101 and 102 for slidably receiving a first and a second platenprojection 111 and 112 extending from opposed ends of the platen 82. Thefirst and second platen projections 111 and 112 are secured to theplaten 82 by pivots 114 and 116. The pivot 99 enables the platen 82 topivot in a first dimension relative to the horizontal conveyor 30whereas the pivots 114 and 116 enable the platen 82 to pivot in a seconddimension relative to the horizontal conveyor 30. The pivoting of theplaten 82 in two dimensions relative to the horizontal conveyor 30allows the downwardly facing portion 121 of the case heater 84 to heatthe entire upper perimeter of the battery case 12 notwithstanding anydefects in the upper periphery of the battery case 12. For example, someportions of the upper perimeter of the battery case 12 may vary two tofour hundredths of an inch from other portions of the upper perimeter ofthe battery case 12. The pivots 99, 114 and 116 allow the case heater 84to engage with the entire perimeter of the battery case 12 irrespectiveof these defects in the upper periphery of the battery case 12 to ensurethat the entire periphery of the battery case 12 is properly heated forenabling the closure 11 to be properly sealed to the battery case 12.

FIG. 8 illustrates the first and second platen projections 111 and 112being slidably received within the first and second slots 101 and 102.The first and second platen projections 111 and 112 and the first andsecond slots 101 and 102 enables the platen 82 to be readablyinterchanged with a standby platen (not shown) when it is desired toseal a different size battery case closure to a battery case. Since theplaten 82 is readily interchangeably, the standby platen (not shown) maybe heated in a standby condition and interchanged with the platen 82disposed on the platen carrier 80 wile both the platen 82 and thestandby platen (not shown) are in a heated condition. This eliminatesthe need for down time on the production line caused by the timerequired for the standby platen (not shown) to obtain a proper operatingtemperature.

FIG. 9 is an enlarged partial view of FIG. 8 illustrating the platen 82including the case heater 84 being disposed on a downwardly facingportion 121 and the closure heater 86 being disposed on an upwardlyfacing portion 122. Preferably, the case heater 84 and the closureheater 86 are separated by an insulator 123. The case heater 84 includescase heating elements 124 whereas the closure heater 86 includes closureheating elements 126. Preferably, each of the case heating elements 124and the heating elements 126 have an independent temperature controls(not shown). Accordingly, the temperature of the case heater 84 forheating the battery cases 12 may be set independently of the temperatureof the closure heater 86 for heating the battery closures 11.

FIGS. 1-6 illustrate a receiver carrier 130 being mounted relative tothe column 70 for vertically moving a closure receiver 132 between athird vertical position shown in FIGS. 5 and 6 and a fourth verticalposition.

As best shown in FIGS. 5, 6, 5A and 6A, the receiver carrier 130comprises a cylindrical barrel 136 for vertically mounting the receivercarrier 130 relative to the vertical column 70. The cylindrical barrel136 of the receiver carrier 130 supports a generally U-shape mounting138.

FIG. 10 is an enlarged exploded isometric view of the receiver carrier130 and the closure receiver 132. The generally U-shape mounting 138includes a first and a second slot 141 and 142 for slidably receiving afirst and a second closure receiver projection 151 and 152 extendingfrom opposed ends of the closure receiver 132.

FIG. 11 illustrates the first and second closure receiver projection 151and 152 being slidably received within the first and second slots 141and 142. The first and second closure receiver projections 151 and 152and the first and second slots 141 and 142 enables the closure receiver132 to be interchanged with a standby closure receiver (not shown) whenit is desired to seal a different size battery case closure to a batterycase.

FIG. 12 is an enlarged partial view of FIG. 11 illustrating a first anda second adjustable stop 154 and 156 shown as threaded stops. The firstand second adjustable stops 154 and 156 enable the proper positioning ofthe first and second closure receiver projections 151 and 152 within thefirst and second slots 141 and 142. The first and second adjustablestops 154 and 156 enables the closure receiver 132 to be rapidlyinterchanged with a standby closure receiver (not shown). Thiseliminates the need for down time on the production line caused by thetime required for changing the closure receiver 132. Preferably, stopsof similar construction are incorporated into the first and secondplaten projections 111 and 112 shown in FIGS. 7 and 8.

As best shown in FIG. 10, the closure receiver 132 comprises a first anda second closure receiver portion 161 and 162 disposed on opposed sidesof the closure receiver 132. Each of the first and second closurereceiver portions 161 and 162 include a plurality of alignment cones 164for engaging with apertures within the battery closure 11. The pluralityof alignment cones 164 align the battery closure 11 relative to each ofthe first and second closure receiver portions 161 and 162.

Each of the first and second closure receiver portions 161 and 162include a closure retainer 166 for retaining a battery closure 11 oneach of the first and second closure receiver portions 161 and 162.Preferably, the closure retainers 166 comprise a plurality of vacuumcups 168 connected to a vacuum source (not shown). The plurality ofvacuum cups 168 retain the battery closure 11 in the aligned position onthe plurality of alignment cones 164 on each of the first and secondclosure receiver portions 161 and 162. Although the closure retainers166 has been shown as a plurality of vacuum cups 168, it should beunderstood that the closure retainers 166 may be mechanical devices.

The closure receiver 132 comprises a first and a second rotatable mount171 and 172 for rotatably mounting the closure receiver 132 to thereceiver carrier 130. A closure receiver rotating drive 174 rotates theclosure receiver 132 between a first and a second rotational position.In the first rotational position, the first closure receiver portion 161faces upwardly. In the second rotational position, the second closurereceiver portion 162 faces upwardly. Preferably, the closure receiverrotating drive 174 is a motor such as a fluid or an electric motor.

FIG. 13 is an enlarged view of the column 70 in a first adjustedposition whereas FIG. 13A is an enlarged view of the column 70 in asecond adjusted position. The adjuster 72 adjusts the vertical positionof the vertical column 70 relative to the horizontal conveyor 30. Theadjuster 72 is shown as a jack incorporating an adjustment handle 74 foradjusting the vertical position of the vertical column 70 foraccommodating for a different size battery case 12. It should beunderstood that the manual adjustment handle 74 may be automaticallyadjusted through the use of a computer control. As the column 70 isadjusted between the first adjusted position shown in FIG. 13 and thesecond adjusted position shown in FIG. 13A, the gear 92 secured to thecylindrical barrel 88 maintains engagement with the pinion gear 94independent of the vertical position of the column 70.

FIGS. 14 and 14A illustrate a platen carrier drive 180 and a receivercarrier drive 220 for respectively vertically moving the platen carrier80 and the receiver carrier 130 on the column 70. The platen carrierdrive 180 comprises the cylindrical barrel 88 having a first and asecond end member 181 and 182 adjacent a first and a second O-ringgroove 184 and 186. A first and a second O-ring 187 and 189 is disposedwithin the first and second grooves 184 and 186 with the first andsecond end members 181 and 182 retaining the first and second O-rings187 and 189 within the first and second grooves 184 and 186. The firstand second O-rings 187 and 189 seal the first and second end members 181and 182 of the cylindrical barrel 88 to the column 70. An annular piston190 extends from the column 70 to be in sealing engagement with acylindrical wall 192 of the cylindrical barrel 88 to define a first anda second chamber 201 and 202. A first and second conduit 211 and 212extend through the column 70 and communicate with the first and secondchambers 201 and 202, respectively.

In a similar manner, the receiver carrier drive 220 comprises thecylindrical barrel 136 having a first and a second end member 221 and222 adjacent a first and a second O-ring groove 224 and 226. A first anda second O-ring 227 and 229 is disposed within the first and secondgrooves 224 and 226 with the first and second end members 221 and 222retaining the first and second O-rings 227 and 229 within the first andsecond grooves 224 and 226. The first and second O-rings 227 and 229seal the first and second end members 221 and 222 of the cylindricalbarrel 136 to the column 70. An annular piston 230 extends from thecolumn 70 to be in sealing engagement with a cylindrical wall 232 of thecylindrical barrel 136 to define a first and a second chamber 241 and242. A first and second conduit 251 and 252 extend through the column 70and communicate with the first and second chambers 241 and 242,respectively.

FIG. 14 illustrates the closure receiver 132 in a lowered position. Whena fluid is driven into the first chamber 241 through the first channel251, the fluid filling the first chamber 241 forces the first chamber241 to expand thereby raising the cylindrical barrel 136 relative to thecolumn 70.

FIG. 14A illustrates the flow of the fluid into the first chamber 241through the first channel 251. As the fluid is driven into the firstchamber 241 through the first channel 251, the fluid is allowed to flowfrom the second chamber 242 through the second channel 252. The flow ofthe fluid into the first chamber 241 and the flow of the fluid from thesecond chamber 242 results in the closure receiver 132 being moved intothe raised position as shown in FIG. 16.

Conversely, when a fluid is driven into the second chamber 242 throughthe second channel 252, the fluid filling the second chamber 242 forcesthe second chamber 242 to expand thereby lowering the cylindrical barrel136 relative to the column 70. As the fluid is driven into the secondchamber 242 through the second channel 252, the fluid is allowed to flowfrom the first chamber 241 through the first channel 251. The flow ofthe fluid into the second chamber 242 and the flow of the fluid from thefirst chamber 241 results in the closure receiver 132 being moved intothe lowered position as shown in FIG. 14.

The vertical movement of the platen carrier 80 is accomplished by theplaten carrier drive 180 in a manner similar to the vertical movement ofthe receiver carrier 130 by the receiver carrier drive 220. Theelongation of the pinion gear or drive 94 enables the continuousengagement with the gear 92 independent of the vertical position of thecolumn 70.

The first and second conduits 211 and 212 as well as the first andsecond conduits 251 and 252 extend through the column 70 and communicatewith the first and second chambers 201 and 202 and the first and secondchambers 241 and 242, respectively. Accordingly, all conduits 211 and212 and 251 and 252 required for the vertical movement of the platencarrier 80 and the receiver carrier 130 on the column 70 are locatedinternal the column 70. It should be appreciated by those skilled in theart that the column 70 may be a shaft disposed in a horizontalorientation or the like.

FIGS. 15-17 illustrate a control system 260 for moving the platencarrier 80 and the receiver carrier 132 as shown in FIGS. 14 and 14A.Although the control system 260 is shown connected to the conduits 211and 212 for vertically moving the platen carrier 80, it should beunderstood that the control system 260 may be used for moving thereceiver carrier 130. Furthermore, although the control system 260 isshown controlling fluid actuators, it should be understood that thecontrol system 260 may be used for controlling any type of actuators.

A fluid source 261 is connected by a conduit 262 to a low flow regulator264. A conduit 266 connects the low flow regulator 264 to a high flowregulator 268. The outputs of the low flow regulator 264 and the highflow regulator 268 are connected to a first valve 271. The low flow rateregulator 264 provides a fluid under pressure having a low flow rate tothe first valve 271. The high flow rate regulator 268 provides a fluidunder pressure having a high flow rate to the first valve 271.

The first valve 271 is connected through a fluid pressure sensor 273 toa second valve 272. The output of the second valve 272 is connected byconduits 276 and 277 to the conduits 211 and 212 located within thecolumn 70. Electrical connectors 281-283 connect the first and secondvalves 271 and 272 and the fluid pressure sensor 273 to the electricalcontrol 270. A location sensor 274 is connected by an electricalconnector 284 to the electrical control 270.

FIG. 15 is an enlarged view illustrating the platen carrier 80 and thecase heater 84 being moved into a raised position at a high rate ofspeed. The high flow rate regulator 268 provides fluid under pressurehaving a high flow rate to the first valve 271. The first valve 271connects the high flow rate fluid through the fluid pressure sensor 273to the second valve 272. The second valve 272 directs the high flow ratefluid to the first chamber 201 for moving the platen carrier 80 and thecase heater 84 into a raised position. The high flow rate fluid from thehigh flow rate regulator 268 moves the platen carrier 80 and the caseheater 84 at a high rate of speed. The location sensor 274 senses theposition of the platen carrier 80.

FIG. 16 is an enlarged view illustrating the platen carrier 80 and thecase heater 84 being moved into a lowered position at a high rate ofspeed. The high flow rate regulator 268 provides fluid under pressurehaving a high flow rate to the first valve 271. The first valve 271connects the high flow rate fluid through the fluid pressure sensor 273to the second valve 272. The second valve 272 directs the high flow ratefluid to the second chamber 202 for moving the platen carrier 80 and thecase heater 84 into a lowered position. The high flow rate fluid fromthe high flow rate regulator 268 moves the platen carrier 80 and thecase heater 84 at a high rate of speed. The location sensor 274 sensesthe position of the platen carrier 80.

FIG. 17 is an enlarged view illustrating the platen carrier 80 and thecase heater 84 being moved into a lowered position at a low rate ofspeed. When the case heater 84 engages the battery case 12, an increaseof pressure is sensed by the fluid pressure sensor 273. An output of thefluid pressure sensor 273 provides a signal along electrical connector283 to the electrical control 270. The electrical control 270 activatesthe first valve 271 to move to the position shown in FIG. 17.

The low flow rate regulator 264 provides fluid under pressure having alow flow rate to the first valve 271. The first valve 271 connects thelow flow rate fluid through the fluid pressure sensor 273 to the secondvalve 272. The second valve 272 directs the low flow rate fluid to thesecond chamber 202 for moving the platen carrier 80 and the case heater84 into a lowered position. The low flow rate fluid from the low flowrate regulator 264 moves the platen carrier 80 and the case heater 84 ata low rate of speed. The location sensor 274 senses the position of theplaten carrier 80.

The low flow rate fluid from the low flow rate regulator 264 moves theplaten carrier 80 and the case heater 84 at a low rate of speed afterengagement with the battery case 12. The low rate of speed of the platencarrier 80 after engagement with the battery case 12 enables the caseheater 84 to move at a slow rate of speed during the heating and meltingof the battery case 12. The case heater 84 moving at a slow rate ofspeed during the heating and melting of the battery case 12 insures anaccurate and total heating and an accurate and total heating of theupper periphery of the battery case 12.

The use of the high flow rate regulator 268 and a low flow rateregulator 264 provides fluid under pressure having a high flow rate tomove the case heater 84 at a high rate of speed toward the battery case12 and to move the case heater 84 at a low rate of speed afterengagement with the battery case 12.

An alternate pressure sensor 275 is located between the platen carrier80 and case heater 84. The alternate pressure sensor 275 sense apressure caused by the contact between the case heater 84 and thebattery case 12. The alternate pressure sensor 275 is an alternate tothe fluid pressure sensor 273. An output of the alternate pressuresensor 275 provides a signal along electrical connector 285 to theelectrical control 270. The electrical control 270 activates the firstvalve 271 to move to the position shown in FIG. 17. Although thepressure sensors 273 and 275 have been shown as fluid pressure sensors,it should be understood that optical, magnetic, electrical or mechanicalpressure sensors may be incorporated within the present invention.

FIG. 18 is an enlarged isometric view of the first battery case 12A onthe conveyor 30 with case stop 300 being disposed in a first position.The case stop 300 comprises a major case stop 301 and a minor case stop302 located on a stop frame 304. A spacer stop 312 is positioned on thestop frame 304. The stop frame 304 is mounted for pivotable movement ona pivot 306 relative to the frame 25 and the conveyor 30. The major casestop 301 is adjusted by the adjustment 307 for stopping the firstbattery case 12A in the proper location. An adjustment 308 allows thepositioning of the minor case stop 302.

FIG. 18 illustrates the first battery case 12A being moved on conveyor30 to strike the major case stop 301. The major case stop 301 is longerthan the minor case stop 302 allowing the major case stop 301 to stopthe first battery case 12A as shown in FIG. 18, while the first batterycase 12A passes by the minor case stop 302.

FIG. 19 illustrates the pivoting of the stop frame 304 on pivot 306 tomove the first battery case 12A into engagement with a side stop 310. Inaddition, the minor case stop 302 positions the first battery case 12Abetween the major case stop 301 and the minor case stop 302 and pressagainst the side stop 310.

When the stop frame 304 is in the position as shown in FIG. 19, thefirst battery case 12A is held in position between the major and minorcase stops 301 and 302, the stop frame 304 and side stop 310.Accordingly, the first battery case 12A is immobilized during theheating and sealing operation. The spacer stop 312 functions to stop thesecond battery case 12B to maintain a space between the first batterycase 12A and the second battery case 12B.

FIG. 20 illustrates the movement of the stop frame 304 into a thirdposition whereat the first battery case 12A containing the case closure11A is allowed to pass by the major case stop 301. When the stop frame304 is placed into position as shown in FIG. 20, the first battery case12A and the case closure 11A is allowed to be moved from the conveyor 30to the output conveyor 60.

The stop frame 304 is moved into the position as shown in FIG. 18 forenabling the major case stop 301 to interrupt the movement of the secondbattery case 12B. Concomitantly therewith, the second battery case 12Bis moved on the horizontal conveyor 30 as shown in FIG. 20. After thefirst battery case 12A with the case closure 11A passes the major casestop 301, the stop frame 304 is moved into position as shown in FIG. 18enabling the major case stop 301 to stop the movement of the secondbattery case 12B on the horizontal conveyor 30.

The stop frame 304 and the major and minor battery case stops 301 and302 secure the battery case in proper position for the heating andsealing process. The adjustments 307 and 308 enable the rapid change ofthe major and minor stops 301 and 302 for cases of various sizes.

FIGS. 21-26 illustrate in greater detail the operation of a closureloader 320 for automatically loading battery case closures 11 onto theclosure receiver 132. The closure loader 320 comprises an indexableconveyor 322 having a plurality of separators 324 for receiving abattery case closure 11 between adjacent separators 324. Upon indexingof a separator 324 to a horizontal position, a drive wheel 326 moves theclosure onto a plate 328 against the stop 329. The plate 328 and stop329 properly position the battery case closure for grasping by theapparatus as will be hereinafter described. The closure loader 320comprises an arm 330 pivotably mounted on a shaft 332 and verticallymovable between a retracted position as shown in FIG. 21 and extendedposition as shown in FIG. 22. The arm 330 supports a jaw 334 forgrasping a portion of the battery case closure 11 such as a projection11P extending from each of the battery case closures 11.

FIG. 21 illustrates the battery case closure 11A resting on the support328 against the stop 329. The arm 330 is in the retracted position androtatable disposed above the projection 11P of the battery case closure11A.

FIG. 22 illustrates the movement of the arm 330 from the retractedposition as shown in FIG. 21 to the extended position as shown in FIG.22. The jaws 334 grasp the projection 11P of the battery case closure11A.

FIG. 23 illustrates the movement of the arm 330 from the extendedposition to the retracted position thereby lifting the battery caseclosure 11A from the surface 328.

FIG. 24 illustrates the rotation of the arm 330 on shaft 332. Thebattery case closure 11A is positioned over the first closure receiverportion 161 of the closure receiver 132.

FIG. 25 illustrates the movement of the arm 330 from the retractedposition to the extended position to deposit the battery closure 11Aonto the first closure receiver portion 161 of the closure receiver 132.The battery closure 11A is retained on the closure retainer 166 by theplurality of vacuum cups 168 as heretofore described.

FIG. 26 illustrates the movement of the arm 330 into the retractedposition. The arm 330 may then be rotated into the position as shown inFIG. 21 to repeat the cycle to load the battery closure 11B onto thesecond closure receiver portion 162.

FIGS. 27-38 illustrate the sequence of operation of the apparatusesheretofore described.

FIG. 27 illustrates the initial condition with the battery case 12A onthe input conveyor and the battery case closure 11A positioned on theclosure loader 320.

FIG. 28 illustrates the movement of the battery case 12A from the inputconveyor 50 to the horizontal conveyor 30. The battery case 12A will bepositioned by the stops as described with references to FIGS. 18-20.Concomitantly therewith, the battery case closure 11A is placed on thefirst closure receiving portion 161 of the closure receiver 132. Theclosure 11A is placed upon the closure receiver 132 in a manner similarto the closure loader 320 shown in FIGS. 21-26.

FIG. 29 illustrates the rotation of the closure receiver 132 on therotatable mounts 171 and 172 shown in FIGS. 10 and 11. FIG. 29 alsoillustrates the movement of a second battery case 12B onto the inputconveyor 50.

FIG. 30 shows the movement of the platen 82 into a position disposedbetween the battery case 12A and the battery case closure 11A. Themovement of the platen 82 is a rotational movement on the column 70 asshown with reference to FIGS. 5A to 6B.

FIG. 31 illustrates the downward movement of the platen 82 and theclosure receiver 132 as the case heater 84 heats the upper periphery ofthe battery case 12A and whereat the closure heater 86 heats the lowerperiphery of the battery case closure 11A. The vertical movement of theplaten 82 and the closure receiver 132 is shown with reference to FIGS.14 and 14A.

FIG. 32 illustrates the movement of the platen 82 into a second verticalposition and the movement of the closure receiver 132 into a fourthvertical position.

FIG. 33 illustrates the rotational movement of the platen 82 from afirst rotational movement to a second rotational position on the column70 as heretofore described. FIG. 33 also illustrates the insertion of abattery case closure 11B onto the second closure receiving portion 162of the closure receiver 132.

FIG. 34 illustrates the downward movement of the closure receiver 132for engaging the closure 11A with the battery case 12A for sealing thebattery case closure to the battery case.

FIG. 35 illustrates the movement of the closure receiver 132 from thethird vertical position to the fourth vertical position after thebattery case closure 11A is sealed to the battery case 12A.

FIG. 36 illustrates the movement of the battery case 12A and associatedbattery case closure 11A from the horizontal conveyor 30 to the outputconveyor 60.

FIG. 37 shows the rotation of the case closure receiver 132 such thatthe second closure receiving portion 162 is facing in a downwarddirection.

FIG. 38 illustrates the movement of the battery case 12B from the inputconveyor to the horizontal conveyor 32. It should be apparent that thesequence can now be repeated for sealing the battery case closure 11B tothe battery case 12B.

The foregoing apparatus has disclosed a simple and reliable machine forheat sealing a battery case closure to a battery case. It should beappreciated by those skilled in the art that the various aspects of theapparatus may be automated and be computer controlled. Conversely, whendesired, the many aspects of the machine could be operated under amanual control.

The operation of the apparatus provides extremely good alignment due tothe fact that all movements are substantially centered around a centralcolumn 70. Furthermore, both the platen 82 and the closure receiver areallowed to pivot in two dimensions for allowing for various tolerancesin the battery case and/or closure. The unique aspects of the quickchange of the platen and the closure receiver allows the apparatus to bechanged over for accommodating different size batteries. In addition,the use of fluid channels within the column greatly simplify thehydraulics of the apparatus and enhance the reliability to virtuallyeliminate hydraulic leaks within the column. The apparatus operates at avery high speed and is very compact allowing the apparatus to beinstalled in virtually any battery assembly facility.

Although the apparatus has been described with reference to a caseheater 84 for sealing the battery case closure 11 to the battery case12, it should be understood that other types of sealing methods may beused such as ultrasonic welding or solvent bonding to secure the batterycase closure 11 to the battery case 12. In such a situation, the caseheater 84 may be removed and a sealer such as an ultrasonic welder orsolvent dispenser is inserted into the apparatus in place of the caseheater 84 as heretofore described.

Although the invention has been described in its preferred form with acertain degree of particularity, it is understood that the presentdisclosure of the preferred form has been made only by way of exampleand that numerous changes in the details of construction and thecombination and arrangement of parts may be resorted without departingfrom the spirit and scope of the invention.

What is claimed is:
 1. The method of heating a battery case with a caseheater, comprising the steps of: rapidly moving the case heater relativeto the battery case into mutual engagement; and slowly moving the caseheater relative to the heated battery case a predetermined distance tomelt the battery case.
 2. The method of heating a battery case with acase heater as set forth in claim 1, wherein the step of slowing movingthe case heater relative to the heated battery case includes melting thebattery case the aforementioned predetermined distance.
 3. The method ofheating a battery case with a case heater as set forth in claim 1,wherein the step of slowly moving the case heater relative to the heatedbattery case includes completely melting an upper periphery of thebattery case.
 4. The method of heating a battery case with a caseheater, comprising the steps of: rapidly moving the case heater towardthe battery case; sensing the engagement of the case heater with thebattery case; and slowly moving the case heater a predetermined distanceto melt the battery case the aforesaid predetermined distance.
 5. Themethod of heating a battery case with a case heater as set forth inclaim 4, wherein the step of sensing the engagement of the case heaterwith the battery case includes sensing an increase in pressure caused bythe contact between the case heater and the battery case.
 6. The methodof heating a battery case with a case heater as set forth in claim 4,wherein the step of slowly moving the case heater relative to the heatedbattery case includes completely melting an upper periphery of thebattery case.
 7. The method of heating a battery case with a caseheater, comprising the steps of: rapidly moving the case heater towardthe battery case by fluid under pressure having a high flow rate;sensing the engagement of the case heater with the battery case bysensing an increase in fluid pressure; and slowly moving the case heaterby fluid under pressure having a low flow rate a predetermined distanceto completely melt an upper periphery of the battery case.
 8. The methodof heating a battery case with a case heater as set forth in claim 7,wherein the step of slowly moving the case heater relative to the heatedbattery case includes melting the battery case the aforementionedpredetermined distance.
 9. The method of heating a battery case with acase heater as set forth in claim 7, wherein the step of slowly movingthe case heater relative to the heated battery case includes completelymelting an upper periphery of the battery case.